Method for manufacturing callipers for disc brakes with forced cap

Abstract

A method for manufacturing callipers for disc brakes. The calliper includes a body in which cylindrical chambers are formed inside which pistons run bearing pads intended for acting on the disc of the brake during the braking step. The method includes the steps of providing a body provided with a slit intended for receiving the disc of the brake and with a pair of cavities aligned transversely to the slit on opposite sides of the slit. The cavities are intended for forming a pair of cylindrical chambers. One of the cavities has a first opening on the slit and a second opening to the outside of the body at which there is a tapered portion with a decreasing section towards the outside of the body. Closing the second opening is a cap applied in the cavity by the slit. The cap has a tapered portion that is forced at the tapered portion of the second opening to form a cylindrical chamber of the calliper.

1. Method for manufacturing callipers for disc brakes of the type comprising a body in which there are formed cylindrical chambers inside which pistons slide bearing pads intended for acting on the disc of the brake during braking, the method comprising the steps of:
 providing a body having a slit intended for receiving the disc of the brake and with a pair of cavities, aligned transversely to the slit on opposite sides of the slit and intended for forming a pair of cylindrical chambers, one of said cavities having a first opening on the slit and a second opening on the outside of the body at which said one of the cavities has a tapered portion with a section decreasing to the outside of the body, 
 providing a cap designed to be applied in said one of the cavities from the slit for closing said second opening to form a cylindrical chamber of the calliper, the cap having a tapered portion adapted to correspond to the tapered portion of the second opening, and 
 applying the cap to the second opening by forcing the tapered portion of the cap into contact with the tapered portion of the second opening to obtain a forced coupling between the tapered portion of the cap and the tapered portion of the second opening in an absence of sealing washers between the body and the cap, the cap having a perimeter groove located between the conical portion and the cylindrical portion, the groove avoiding contact with a wall of said one of the cavities when the cap is applied by forcing the tapered portion of the cap into contact with the tapered portion of the second opening. 
 
     
     
       2. Method according to  claim 1 , wherein the tapered portion of the cap and the tapered portion of said one of the cavities have conical surfaces to form a respective conical portion of the cap and of the one cavity. 
     
     
       3. Method according to  claim 2 , wherein the surfaces of the tapered portions have a tilt between 3° and 5° compared with an axial direction of said one of the cavities. 
     
     
       4. Method according to  claim 1 , wherein the body is obtained by die-casting and is machined on the surfaces of the cavities with a tool inserted through said second opening before the cap is applied. 
     
     
       5. Method according to  claim 2 , wherein said one of the cavities has a cylindrical portion that is serial to the conical portion towards the outside of the body of the calliper, the cap having a cylindrical portion that is complementary to the cylindrical portion of said one of the cavities and that is suitable for engaging therein when the cap is forced into the second opening of the one cavity. 
     
     
       6. Method according to  claim 1 , wherein external surface machining is performed at the external face of the cap after forcing of the cap. 
     
     
       7. Calliper for disc brakes made using a method according to  claim 1 . 
     
     
       8. Method for manufacturing callipers for disc brakes of the type comprising a body in which there are formed cylindrical chambers inside which pistons slide bearing pads intended for acting on the disc of the brake during braking, the method comprising the steps of:
 providing a body provided with a slit intended for receiving the disc of the brake and with a pair of cavities aligned transversely to the slit on opposite sides of the slit intended for forming a pair of cylindrical chambers, one of said cavities having a first opening on the slit and a second opening on the outside of the body at which there is a tapered portion with a section decreasing to the outside of the body, and 
 closing said second opening with a cap applied in the cavity by the slit, the cap having a tapered portion that is forced coupled at the tapered portion of the second opening to form a cylindrical chamber of the calliper, the tapered portions of the cap and of the cavity having conical surfaces, the tapered portions having a tilt between 3° and 5° compared with an axial direction of the cavity, the cap having a perimeter groove located between the conical portion and a cylindrical portion, the groove avoiding contact with a wall of said one of the cavities when the cap is applied by forcing the tapered portion of the cap into contact with the tapered portion of the second opening.